Spoked rotor with tapered pole segments

ABSTRACT

A rotor includes a plurality of arcuately arranged magnets and a core including a plurality of arcuately arranged pole segments alternating with the magnets, such that each of the magnets is at least in part interposed between adjacent pole segments. The pole segments at least in part cooperatively present an annular core face at least in part defining a core envelope. Each of the pole segments includes a main body and a pair of ears. The main body presents a body face extending concentrically with the axis, disposed along the envelope, and presenting a pair of arcuately spaced apart body edges. The ears each extend generally arcuately outwardly from a corresponding body edge and present a substantially flat ear face extending directly from the body edge. Each of the ear faces is disposed radially inside the envelope.

CROSS-REFERENCE TO RELATED APPLICATIONS Priority Application

The present application claims priority from U.S. ProvisionalApplication No. 62/315,971, filed Mar. 31, 2016, the entire disclosureof which is hereby incorporated by reference herein.

Contemporaneously Filed Application

The present application is filed contemporaneously with U.S. patentapplication Ser. No. ______, entitled SPOKED ROTOR WITH INNER STRUCTURALBRIDGES PROVIDING LOW FLUX LEAKAGE, the entire disclosure of which ishereby incorporated by reference herein.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates generally to an electric motor. The motorpreferably improves system efficiency in applications including but notlimited to heating, ventilation, and air conditioning (HVAC) systems;pumps; and home appliances. Yet further, the motor preferably reducesoperational vibration and/or noise. More particularly, the motorpreferably concentrates magnetic flux and reduces flux leakage,resulting in higher power density, in addition to reducing coggingtorque, torque ripple, and noise. Yet further, the motor ideally has lowmanufacturing complexity, high structural rigidity, and reduced activematerial and cost.

2. Discussion of the Prior Art

Electric motors are conventionally used in applications including butnot limited to heating, ventilation, and air conditioning (HVAC)systems; pumps; and home appliances. Such motors conventionally includea stator and a rotor. The rotor conventionally includes a generallytoroidal rotor core and a plurality of surface magnets mounted about aperimeter of the core.

SUMMARY

According to one aspect of the present invention, a rotor is providedfor use in an electric motor. The rotor is rotatable about an axis. Therotor includes a plurality of magnets arranged arcuately about the axis.The rotor further includes a core including a plurality of arcuatelyarranged pole segments alternating with the magnets, such that each ofthe magnets is at least in part interposed between adjacent polesegments. The pole segments at least in part cooperatively present anannular core face. The core face at least in part defines a coreenvelope. The envelope defines a core radius. Each of the pole segmentsincludes a main body and a pair of ears. The main body presents a bodyface extending concentrically with the axis and disposed along theenvelope. The body face presents a pair of arcuately spaced apart bodyedges. The ears each extend generally arcuately outwardly from acorresponding one of the body edges. Each of the ears presents asubstantially flat ear face extending directly from the correspondingone of the body edges. Each of the ear faces defines a taper anglerelative to a tangent plane defined at the corresponding one of the bodyedges. Each of the ear faces is disposed radially inside the envelopeand presents a radially innermost ear edge disposed radially inwardly ofsaid envelope by an ear recess distance. The taper angle is betweenabout 4 degrees and about 8 degrees. The ear recess distance is betweenabout 0.2% and 0.5% of said core radius.

This summary is provided to introduce a selection of concepts in asimplified form. These concepts are further described below in thedetailed description of the preferred embodiments. This summary is notintended to identify key features or essential features of the claimedsubject matter, nor is it intended to be used to limit the scope of theclaimed subject matter.

Various other aspects and advantages of the present invention will beapparent from the following detailed description of the preferredembodiments and the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Preferred embodiments of the present invention are described in detailbelow with reference to the attached drawing figures, wherein:

FIG. 1 is a perspective view of a motor in accordance with a firstpreferred embodiment of the present;

FIG. 2 is a perspective view of the motor of FIG. 1, with the shellremoved to expose the rotor and the stator and with a portion of therotor overmolding removed to reveal the rotor core and magnets;

FIG. 3 is a top perspective view of a single lamination of the rotorcore of FIG. 2;

FIG. 4 is a top plan view of the rotor core of FIG. 2;

FIG. 5 is an exploded top perspective view of a pair of adjacentlaminations of the rotor core of FIGS. 2 and 4;

FIG. 6 is a top perspective view of the rotor core and magnets of FIG.2, with several magnets removed to illustrate the rotor core design;

FIG. 6a is an enlarged, fragmentary top perspective view of a portion ofthe rotor core of FIG. 6, particularly illustrating details of theinterior bridges;

FIG. 7 is a partially fragmentary cross-sectional view of the rotor coreof FIG. 6 and others, taken along line 7-7 of FIG. 6, and particularlyillustrating the offset nature of the rotor laminations and consequentformation of axially discontinuous interior structural bridges;

FIG. 8 is an enlarged, fragmentary top plan view of a portion of therotor core of FIG. 6 and others, particularly illustrating geometricfeatures thereof;

FIG. 9a is a further enlarged, fragmentary top view of the portion ofthe rotor core of FIG. 8, further illustrating geometric featuresthereof;

FIG. 9b is a still further enlarged, fragmentary top view of the portionof the rotor core of FIGS. 8 and 9 a, further illustrating geometricfeatures thereof; and

FIG. 10 is a top perspective view of a single laminations of the portionof the rotor core shown in FIG. 9 a.

The drawing figures do not limit the present invention to the specificembodiments disclosed and described herein. The drawings are notnecessarily to scale, emphasis instead being placed upon clearlyillustrating the principles of the preferred embodiments.

Furthermore, directional references (e.g., top, bottom, front, back,side, etc.) are used herein solely for the sake of convenience andshould be understood only in relation to each other. For instance, acomponent might in practice be oriented such that faces referred to as“top” and “bottom” are sideways, angled, inverted, etc. relative to thechosen frame of reference.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is susceptible of embodiment in many differentforms. While the drawings illustrate, and the specification describes,certain preferred embodiments of the invention, it is to be understoodthat such disclosure is by way of example only. There is no intent tolimit the principles of the present invention to the particulardisclosed embodiments.

Motor Overview

With initial reference to FIGS. 1 and 2, an electric motor 10 isprovided for use in a machine. In a preferred embodiment, the motor 10is configured for use in a heating, ventilation, and air conditioning(HVAC) system; a pump; or a home appliance. However, alternativeapplications fall within the scope of the present invention.

In a preferred embodiment, the motor 10 has a horsepower range betweenabout one-tenth ( 1/10) hp and about ten (10) hp. More preferably, thehorsepower range is between about one-sixth (⅙) hp and about five (5)hp. Most preferably, the horsepower range is between about three (⅓) hpand about one (1) hp. However, higher or lower horsepower motors fallwithin the scope of some aspects of the present invention.

Preferably, the motor 10 is a variable speed motor, with an operatingrange from about zero (0) rpm to about four thousand (4,000) rpm.However, it is within the ambit of the present invention for the motorto be a single-speed motor, a multiple-speed motor, or to have adifferent speed range.

The motor 10 broadly includes a rotor 12 and a stator 14. The rotor 12is rotatable about an axis. In a preferred embodiment, as shown, thestator 14 at least substantially circumscribes the rotor 12, such thatthe motor 10 is an inner rotor motor. It is permissible according tosome aspects of the present invention, however, for the motor to be anouter rotor motor.

As will be discussed in greater detail below, the rotor 12 preferablyincludes a rotor core 16, a plurality of magnets 18, a shaft 20 defininga rotational axis A for the rotor 12, and a retention structure 22.

As will also be discussed in greater detail below, the stator 14preferably includes a stator core 24, an electrically insulativecovering 26 on the stator core 24, and a plurality of coils 28 woundabout the stator core 24.

The motor 10 further preferably includes a housing 30. The housing 30preferably includes a shell 32, a upper endshield 34, and a lowerendshield 36. The shell 32 and the upper and lower endshields 34 and 36,respectively, preferably present a motor chamber 38 that at leastsubstantially receives the stator 14 and the rotor 12.

In a preferred embodiment, the shell 32 extends generallycircumferentially about the stator 14. It is permissible according tosome aspects of the present invention, however, for the shell to extendin such a manner as to provide one or more flat sides, in contrast tothe preferred generally cylindrical form, or to be otherwisealternatively shaped.

The upper endshield 34 preferably supports an upper bearing 40. Thelower endshield 36 preferably support a lower bearing (not shown). Theupper bearing 40 and the lower bearing preferably cooperativelyrotatably support the shaft 20. Alternative or additional bearingssupports or shaft supports may be provided without departing from thescope of the present invention, however.

The upper and lower endshields 34 and 36 are preferably secured to theshell 32 by means of fasteners 42 that also extend through the stator14, although alternative securement means fall within the ambit of thepresent invention.

The housing 30 further preferably includes a controller can 44. In apreferred embodiment, the controller can 44 and the lower endshield 36cooperatively define a controller chamber (not shown) that at leastsubstantially houses a motor controller (not shown). Alternativecontroller locations and/or configurations are permissible, however.

Stator Overview

As noted previously, the stator 14 preferably includes a stator core 24,an electrically insulative covering 26 on the stator core 24, and aplurality of coils 28 wound about the stator core 24.

In a preferred embodiment, the stator 14 is generally toroidal in form.The stator core 24 is likewise preferably generally toroidal in form anddefines an axis B of the stator 14. Preferably, the axis B of the stator14 is coaxial with that of the rotor 12. However, it is permissibleaccording to some aspects of the present invention for the axes to benon-coaxial.

The stator core 24 preferably includes an annular yoke 46 and aplurality of arcuately spaced apart teeth 48 extending at leastgenerally radially from the yoke 46.

Preferably, the teeth 48 extend radially inwardly from the yoke 46(because of the preferred inner rotor motor design), although it ispermissible according to some aspects of the present invention for theteeth to extend generally outwardly (e.g., in the case of an outer rotormotor).

Each tooth 48 preferably includes a generally radially extending arm(not shown) and a generally arcuately extending crown 52 extending fromone end (preferably the radially inner end) of the arm.

Each crown 52 preferably presents a circumferential crown face 54 spacedopposite the yoke 46. The circumferential crown faces 54 preferablycooperatively define an inner radial surface 56 of the stator core 24.In an alternative embodiment in which the motor is an outer rotor motor,however, the crown faces might instead present an outer radial margin ofthe stator core.

In a preferred embodiment, the yokes 46 cooperatively present an outerradial surface 58 of the stator core 24. The outer radial surface 58preferably defines an outer diameter of the stator 14 as a whole.

The stator core 24 preferably has an inner diameter defined by the innerradial surface 56. In a preferred inner rotor motor 10, as illustrated,such inner diameter must necessarily be larger than the outer diameterof the rotor 12. More particularly, as will be discussed in greaterdetail below, the rotor 12 and the stator 14 preferably define a thin,circumferentially extending gap 60 therebetween.

Each pair of adjacent teeth 48 preferably defines a slot 62therebetween. Preferably, the stator core 24 includes twelve (12) teeth48, such that twelve (12) slots 62 are defined. However, it ispermissible according to some aspects of the present invention for thenumber of teeth and, in turn, the number of slots, to vary.

The coils 28 preferably comprise electrically conductive wiring 64. Thewiring 64 is preferably wound about each of the teeth 48 through theslots 62 to form the coils 28, with each of the coils 28 correspondingto one of the teeth 48. More particularly, the wiring 64 is preferablywound about each arm to form the coils 28.

The wiring 64 preferably comprises copper or aluminum, although any oneor more of a variety of electrically conductive materials may be usedwithout departing from the scope of the present invention.

The stator core 24 is preferably a laminated stator core comprising aplurality of axially stacked laminations (not individually shown).However, it is permissible for the stator core to be a solid stator corewithout departing from the scope of the present invention.

The stator core 24 preferably comprises steel. However, it ispermissible without departing from the scope of some aspects of thepresent invention for any one or more of a variety of suitable materialsto be used for the stator core.

As noted previously, an insulative covering 26 is preferably provided onthe stator core 24. The covering 26 preferably comprises an at leastsubstantially electrically insulative material. In a preferredembodiment, for instance, the insulative covering 26 comprises asynthetic resin material. However, any one or more of a variety ofsubstantially electrically insulative materials may be used withoutdeparting from the scope of the present invention.

In a preferred embodiment, the insulative covering 26 comprises aplurality of electrically insulative endcaps 66. However, it is notedthat use of any one or more of a variety of insulation means, includingbut not limited to the use of electrically insulative overmolding,powder- coating, inserts, and/or liners, is permissible according tosome aspects of the present invention. It is also permissible accordingto some aspects of the present invention for the stator core to bedevoid of electrical insulation.

The wiring 64 is preferably wound about the teeth 48 on the outside ofthe endcaps 66, such that the wiring 64 is not in direct contact withthe stator core 24 itself where the endcaps 66 are present. That is, thecovering 26 preferably electrically insulates the stator core 24 fromthe wiring 64 and additionally provides a physical barrier between thestator core 24 and the wiring 64.

Rotor Overview

As noted previously, the rotor 12 preferably includes a rotor core 16, aplurality of magnets 18, a shaft 20, and a retention structure 22.

The rotor core 16 preferably comprises a plurality of pole segments 68arranged arcuately about the axis A (or, alternatively described, aboutthe shaft 20). Similarly, the magnets 18 are preferably arrangedarcuately about the axis A or shaft 20. In a preferred embodiment, asillustrated, the pole segments 68 alternate arcuately with the magnets18, such that each of the magnets 18 is at least in part interposedbetween adjacent pole segments 68.

Preferably, the pole segments 68 are evenly arcuately arranged.Similarly, the magnets 18 are preferably evenly arcuately arranged. Yetfurther, each magnet 18 is preferably centrally positioned betweenadjacent pole segments 68. Each magnet 18 is also preferably in directcontact with adjacent ones of the pole segments 68. It is permissibleaccording to some aspects of the present invention, however, for unevenarrangements or variably spaced arrangements to be used.

In a preferred embodiment, ten (10) pole segments and ten (10) magnets18 are provided, such that the motor 10 is a twelve (12) slot, ten (10)pole motor. However, it is permissible according to some aspects of thepresent invention for other numbers of slots and poles achieving apreferred six (6) slot:five (5) pole ratio to be present. For instance,the motor might in an alternative embodiment include twenty-four (24)slots and twenty (20) poles. Yet further, the motor might instead havean entirely different slot:pole ratio (e.g., 9:10 or 3:2) andcorresponding actual number of slots and poles (e.g., nine (9) slots andten (10) poles, or twelve (12) slots and eight (8) poles) withoutdeparting from the scope of some aspects of the present invention.

Pole Segments

The pole segments 68 preferably each comprise a magnetically conductivemetallic material such as steel. For instance, the pole segments 68might suitably comprise S85H2 steel. It is permissible for any one ormore of a variety of magnetically conductive materials to be used,however. For instance, a steel of an alternative grade might beprovided.

In a preferred embodiment, as will be discussed in greater detail below,the pole segments 68 are interconnected in such a manner as to allow foronly a small amount of transfer of magnetic flux. However, designsenabling significant flux transfer or even completely eliminating fluxtransfer are permissible according to some aspects of the presentinvention.

The rotor core 16 preferably comprises a plurality of axially stackedlaminations 70 that cooperatively define the pole segments 68. Moreparticularly, each lamination 70 preferably defines a plurality of polesegment portions 72, with the pole segment portions 72 cooperativelydefining the pole segments 68.

The laminations 70 in the illustrated embodiment are about twenty-twothousandths (0.022) inches thick, although other thicknesses (e.g., fivetenths (0.5) mm or about one hundred ninety-seven ten-thousandths(0.0197) inches) are permissible without departing from the spirit ofsome aspects of the present invention. Furthermore, it is permissibleaccording to some aspects of the present invention for the rotor core 16to in whole or in part be non-laminated (e.g., monolithically formed).

As will be discussed in greater detail below, the pole segments 68preferably at least in part cooperatively present an annular core face74 and a pair of axially spaced apart, generally radially extendingupper and lower faces 76 and 78 that cooperatively at leastsubstantially define an abstract (i.e., spatially defined) core envelopeC providing axial and radial boundaries to the rotor core 16. Moreparticularly, the core envelope C is preferably an imaginary shape thatgenerally corresponds with the outermost dimensions of the core 16.

In a preferred embodiment, each pole segment 68 preferably includes amain body 82 and a pair of ears 84 each extending generally arcuatelyoutwardly from the body 82 in opposition to each other.

More particularly, each main body 82 preferably presents a body face 86presenting a pair of arcuately spaced apart body margins 88, a pair ofarcuately spaced sides 90 extending generally radially from the bodymargins 88, and an inner face 92 extending between and interconnectingthe sides 90 to present a radially innermost face of the respective mainbody 82.

Each of the ears 84 preferably presents a radially outermost ear face 94extending directly from a corresponding one of the body margins 88. Eachear also presents a radially innermost rear face 96 disposed radiallyinwardly of the corresponding ear face 94 and extending directly from acorresponding one of the sides 90 of the main body 82. Yet further, theears 84 each also preferably present a tip margin 98 spaced generallyarcuately from the main body 82 and extending between andinterconnecting the corresponding ear face 94 and rear face 96.

In a preferred embodiment, the body faces 86 each extend concentricallywith the rotor axis A. That is, each of the body faces 86 extends alonga circular path and presents a center of curvature D coincident with theaxis A, such that the body faces 86 cooperatively define portions of aright circular cylinder. In keeping with the above, each of the bodyfaces 86 presents a radius of curvature E that will be described ingreater detail below in relation to the rotor 12 more broadly. It ispermissible according to some aspects of the present invention, however,for the body faces 86 to present alternative geometries.

The aforementioned right circular cylinder defined by the body faces 86defines the core envelope C. That is, the body faces 86 each aredisposed along the envelope C.

As noted previously, the pole segment sides 90 preferably extendgenerally radially. More particularly, it is preferred that the polesegment sides 90 of a given pole segment 68 each extend inwardly (i.e.,taper) toward each other so as to deviate somewhat from perfectly radialextension. That is, the pole segments 68 are preferably generally wedgeshaped by merit of the tapered sides 90.

Even more particularly, the adjacent sides 90 of each pair of adjacentpole segments 68 preferably extend parallel to one another. As will bediscussed in greater detail below, such shaping is advantageous inrelation to the magnets 18.

In keeping with the above, it is also preferable that the inner face 92is shorter in a generally circumferential/arcuate (or tangential)direction than the body face 86. For instance, in a preferredembodiment, the body face 86 has a body face length F that is betweenabout five (5) times and about ten (10) times a length G of the innerface 92. Most preferably, the body face length F is about eight (8)times the inner face length G. In the illustrated embodiment, forinstance, the inner face 92 has a length G of about fifty thousandths(0.050) inches. The body face 86 has a length F of about four hundredfive thousandths (0.405) inches.

The ear faces 94 are preferably at least substantially flat, althoughcurves and/or other geometric features are permissible according to someaspects of the present invention.

Most preferably, in addition to the aforementioned generally arcuate orcircumferential extension, the ear faces 94 extend radially inwardlyfrom the corresponding body margins 88. That is, each of the ear facesangles radially inwardly so as to be disposed radially inside theenvelope C and define a taper angle H relative to a tangent plane Idefined at the corresponding body margin 88.

Furthermore, each of the ear faces 94 can preferably be described aspresenting a radially innermost ear edge 100 disposed radially inwardlyof the envelope C by an ear recess distance J.

In a preferred embodiment, as illustrated, the taper angle H is betweenabout four (4) degrees and about eight (8) degrees. Most preferably, thetaper angle H is about five and twenty-five hundredths (5.25) degrees.

In a preferred embodiment, the core face 74 or, alternatively stated,the core envelope C defines a core or envelope radius K. As will beapparent to those of ordinary skill in the art, such core or enveloperadius K is preferably equal to the previously described radius ofcurvature E of the body faces 86, such that the body faces 86 may bedescribed as cooperatively defining the core or envelope radius K.

Preferably, the ear recess distance J is between about two tenths (0.2)percent and about five tenths (0.5) percent of the core or enveloperadius K. Most preferably, the ear recess distance J is about thirty-sixhundredths (0.36) percent of the core or envelope radius K. In thepreferred illustrated embodiment, the ear recess distance is aboutfifty-seven ten thousandths (0.0057) inches. In comparison, the core orenvelope radius K and, in turn, the radius of curvature E of the bodyfaces 86) is about one and six tenths (1.6) inches.

The body faces 86 preferably each extend arcuately along a body arcangle L. The ear faces 94 each preferably each extend along an ear arcangle M In a preferred embodiment, the body arc angle L is between aboutequal to and about three (3) times each ear arc angle M. Mostpreferably, the body arc angle L is about two (2) times each ear arcangle M. In the illustrated embodiment, for instance, the body arc angleL is about fifteen (15) degrees, while the ear arc angle M is aboutseven and five tenths (7.5) degrees.

As noted previously, the body faces 86 present a body face length F ofabout four hundred five thousandths (0.405) inches. The ears faces 94each preferably present an ear length N of about two hundred ninethousandths (0.209) inches.

With further regard to pole segment 68 geometry, in a preferredembodiment, the rear faces 96 of the ears 84 and each corresponding oneof the main body sides 90 form an obtuse rear angle O therebetween. Therear angle O is preferably between about one hundred twenty (120) andone hundred fifty (150) degrees. Most preferably, the rear angle O isabout one hundred thirty-five (135) degrees.

The above-described general design and specific geometry achievesseveral unexpected advantages. For instance, provision of a spoked rotor12 (i.e., one using arcuately alternating pole segments 68 and magnets18, rather than, for instance, surface magnets) enables highconcentration of flux from the magnets 18 and a relatively low volume ofcostly active material (e.g., in contrast to non-spoked rotor designs).Furthermore, provision of tapered ears 84 and concentric main body faces86 configured as described above (e.g., in terms of relative angularextent, radius of curvature, taper angle, and recession depth)surprisingly reduces cogging torque and noise while minimizing reductionof active material at the core face 74 (to thereby maximize flux).Alternatively stated, in a preferred embodiment of the presentinvention, cogging torque, torque ripple, and noise are reduced to asuitable degree without excessive increases to the size of the air gap60. In contrast, improper proportioning and/or shaping would result indetrimental effects with regard to cogging torque, noise, and/or fluxconcentration relative to those achieved by the present invention.

The above-described design also eliminates the need for skewedmagnetization ofthe rotor magnets, the provision of specially shaped orskewed stator teeth, lobed (non-concentric) rotor pole segment faces,and other performance-degrading design features. (It is noted thatskewed rotor core designs, although not necessary, fall within the ambitof some aspects of the present invention and will be discussed ingreater detail below.)

Support Structure

In a preferred embodiment, the rotor 12 further includes a supportstructure 102 that at least in part supports the rotor core 16 forrotation with the shaft 20. Preferably, as illustrated, the supportstructure 102 is integrally formed with the rotor core 16 and, moreparticularly, is cooperatively formed by the laminations 70. It ispermissible according to some aspects of the present invention, however,for non-integral formations to be provided. For instance, the polesegments of the core might be secured to the support structure by meansof dovetails or other interlocking geometry.

In a preferred embodiment, the support structure 102 is generallytoroidal and circumscribes the shaft 20. More particularly, the supportstructure 102 presents circumferential inner and outer faces 104 and106. The inner face 104 preferably is fixed to the shaft 20 (e.g., bymeans of an interference fit, mechanical interconnection, etc.) suchthat the support structure 102 rotates with the shaft 20.

Furthermore, although the support structure 102 is preferablynon-integral with the shaft 20, integral formation of the shaft andsupport structure or of all of the shaft, support structure, and corefall within the scope of some aspects of the present invention.

It is preferable that the support structure 102 be disposed radiallyinwardly of the pole segments 68, in keeping with the preferred innerrotor configuration, although outward positioning and accompanyingchanges to the general rotor configuration (e.g., in an outer rotormotor) are permissible according to some aspects of the presentinvention.

Preferably, as will be discussed in greater detail below, the supportstructure 102 includes magnet retaining structure 108. Moreparticularly, magnet retaining structure 108 comprises a plurality ofradially extending, arcuately spaced apart retention nubs 110 configuredto restrict radially inward shifting of corresponding ones of themagnets 18. Alternative or additional means of restricting such shiftingare permissible according to some aspects ofthe present invention,however. For instance, in a preferred embodiment and as discussed ingreater detail below, the retention structure 22 aids in fixation of themagnets 18. Furthermore, the magnets might be instead or additionally besecured or restricted by means of radially inner and/or outer, generallyarcuately extending tabs or other geometric features defined by the polesegments and/or the support structure.

Magnets

Each magnet 18 is preferably generally cuboidal in form. Moreparticularly, each magnet 18 preferably presents a radially innermostface 112, a radially outermost face 114, a pair of circumferentiallyspaced apart side faces 116, and axially spaced apart upper and lowerfaces 118. The faces 112,114,116,118 are preferably at leastsubstantially flat and arranged in a cuboidal manner. It is permissibleaccording to some aspects of the present invention, however, for themagnet shapes to vary (e.g., via the provision of one or more curvedfaces and/or non-orthogonal interfaces between the faces), although thesides of the adjacent pole segments to be complementally shaped.

The radially innermost face 112 of each magnet 18 is preferably spacedfrom but adjacent a corresponding one of the magnet-retention nubs 110of the support structure 102. Similarly, the radially outermost faces114 are preferably spaced from but adjacent the corresponding ones therear faces 96 of corresponding ones the pole segment ears 84.Furthermore, each of the side faces 116 preferably directly abuts acorresponding one of the pole segment sides 90. As noted previously, thesides 90 are preferably generally radially extending. Most preferably,the sides 90 deviate somewhat from perfect radial extension to taperinwardly toward each other. Even more particularly, adjacent sides 90 ofadjacent pole segments 68 extend at least substantially parallel to oneanother. Thus, circumferential and radial shifting of each magnet 18 isat least substantially restricted by the adjacent pole segments 68 andthe support structure 102.

In a preferred embodiment, each magnet 18 is preferably oriented suchthat its polarity is oriented generally tangentially. Furthermore, thedirections of polarity of the magnets 18 are preferably alternated. Moreparticularly, the north pole of a first one of the magnets 18 preferablyfaces the north pole of a second one of the magnets 18, etc. That is,each pole segment 68 preferably abuts only like poles of the adjacentmagnets 18, with the poles segments 68 therefore themselves alternatingin polarity.

It is permissible according some aspects of the present invention,however, for alternatively oriented and/or arranged magnets to beprovided.

In a preferred embodiment, the magnets 18 are permanent magnets.Furthermore, the magnets 18 preferably comprise ferrite. However, othermagnet materials (e.g., neodymium and other rare earth materials) may beused without departing from the scope of the present invention.

Retention Structure

As noted previously, the rotor 12 preferably includes a retentionstructure 22. The retention structure 22 preferably aids in securementof the magnets 18 to the core 16. (Such structure 22 is preferablyprovided in addition to the aforementioned geometric/structural means ofrelative positioning of components—e.g., the magnet retention nubs 110ofthe support structure 102, the rear faces 96 of the pole segments ears84, etc.)

In a preferred embodiment, the retention structure 22 is formed of amagnetically insulative material, such that no magnetic flux or onlynegligible magnetic flux (e.g., the flux corresponding to a flux densityof fifteen (15) mT or less) flows therethrough. More particularly, theretention structure 22 preferably supports and positions the polesegments 68 and the magnets 18 without facilitating flux flow betweenadjacent pole segments 68.

In a preferred embodiment, the retention structure 22 comprises asynthetic resin material. It is permissible according to some aspects ofthe present invention, for part or all of the retention structure toinstead comprise an alternative at least substantially magneticallyinsulative material. For instance, the retention structure might includean aluminum bracket securing the pole segments and magnets, as well asan overmolded shell supporting the bracket.

Yet further, a portion of the retention structure that does not engagethe pole segments and/or the magnets might alternatively be formed of amagnetically conductive material. Such portion would not interfere withthe desired substantial magnetic isolation of the pole segments.

All in all, any one or more of a variety of materials capable ofenabling the features and qualities described herein (e.g., magneticshielding capability, structural rigidity, etc.) may be used to form theretention structure without departing from some aspects of the presentinvention.

Preferably, however, as will be discussed in greater detail below, theretention structure 22 comprises a body 120 overmolded over at leastportions of the pole segments 68 and the magnets 18 so as to secure thepole segments 68 relative to each other, the magnets 18 relative to eachother, and the pole segments 68 and magnets 18 relative to each other.

Such body 120 preferably is formed of a magnetically insulative material(e.g., a plastic) that is an least somewhat flowable (or at leastmalleable) composition capable of being molded into a rigid,self-sustaining body providing the necessary retention capabilitiesdescribed above. The compositions for overmolding according to theinvention will generally include a synthetic resin, such as an organicpolymeric or oligomeric resin that is capable of hardening orcrosslinking during the overmolding process. In many instances, thecomposition will also include a crosslinking agent and/or a catalyst toinitiate crosslinking, since a thermosetting plastic is typicallypreferred.

The body 120 is preferably formed by use of a mold (not shown). Broadlyspeaking, in a preferred method of assembly, the pole segments 68 andmagnets 18 are positioned in the mold to be alternately arcuatelyarranged. The retention structure material is preferably injected intothe mold by any means known in the art to create the overmolded body 120and secure the pole segments 68 and the magnets 18. However, a varietyof suitable molding techniques will be apparent to those of ordinaryskill in the art.

Furthermore, it is permissible according to some aspects of the presentinvention for some or all of such features to be formed by anon-overmolded retention structure or a non-overmolded portion orportions of a partially overmolded retention structure. For instance, aplastic mounting plate might be provided, with the magnets and polesegments being fastened or otherwise secured to the plate after theplate is formed.

Preferably, the retention structure 22 is configured in such a mannerthat the rotor 12 may be magnetized after assembly. However,pre-assembly magnetization is permissible.

Outer Pole-Interconnecting Bridges

In a preferred embodiment, as illustrated, the rotor core 16 includes aplurality of outer bridges 122 extending between and interconnectingadjacent ones of the pole segments 68. More particularly, the outerbridges 122 preferably extend between and interconnect adjacent ears 84of adjacent ones of the pole segments 68. Most preferably, the outerbridges 122 extend from the tip margins 98 of the ears 84.

The outer bridges 122 each preferably present radially inner and outerbridge faces 124 and 126, respectively. The bridge faces 124 and 126 ofa given bridge 122 are preferably parallel to one another, with theouter bridges 122 thereby being at least substantially straight andextending tangentially relative to the core envelope C.

Each ear face 94 defines an ear-bridge angle P with an adjacent one ofthe outer bridge faces 126. Preferably, such angle P is between aboutone hundred seventy-two (172) degrees and about one hundred seventy-six(176) degrees. That is, each ear face 94 preferable angles inwardlybetween about four (4) degrees and about eight (8) degrees from theadjacent outer bridge face 126.

Most preferably, the ear-bridge angle P is about one hundred seventyfour and five tenths (174.5) degrees. That is, the ear face 94preferable angles inwardly about five and five tenths (5.5) degrees fromthe corresponding outer bridge face 126.

The preferred geometry of the outer bridges 122 relative to the polesegments 68 may also be described in terms of the extent to which theradially outer bridge faces 126 are disposed radially inwardly of thecore envelope C (defined, as noted previously, by the body faces 86 ofthe main bodies 82 of the pole segments 68). More particularly, theouter faces 126 are each disposed radially inwardly of the core envelopeC by a bridge recess distance Q. The bridge recess distance Q ispreferably between about thirty-five hundredths (0.35) percent and aboutsixty-five hundredths (0.65) percent of the core or envelope radius K(or, alternatively stated, of the radius of curvature E of thecorresponding body face 86). Most preferably, the bridge recess distanceQ is about five tenths (0.5) percent of the core or envelope radius K.

As noted previously, in a preferred embodiment, the core or enveloperadius K and, in turn, the radius of curvature E, are about one and sixtenths (1.6) inches. The bridge recess distance Q is about eightthousandths (0.008) inches.

Preferably, the outer bridges 122 present a generally radial thicknessR. The thickness R is preferably between about one (1) percent and abouttwo (2) percent of the core or envelope radius K (or body face radius ofcurvature E). Most preferably, the bridge thickness R is about one andfive tenths (1.5) percent of the core or envelope radius K. Morespecifically, in a most preferred embodiment, each bridge thickness R isabout twenty-four thousandths (0.024) inches.

The outer bridges 122 are preferably relatively thin to reduce flux flowbetween adjacent pole segments 68 while nevertheless providingadvantageous structural rigidity to the rotor 12 (e.g., by means ofbracing the pole segments 68 relative to each other). That is, the outerbridges 122 preferably provide beneficial increased rotor rigidity andair gap control while maintaining low flux flow between adjacent polesegments 68. It is permissible according to some aspects of the presentinvention, however, for the bridges to be configured to achievealternative design goals (e.g., thicker bridges might be provided in arotor for which structural rigidity is significantly greater relativeimportance than efficient flux concentration).

It is also noted that provision of the bridges 122 preferably increasesmanufacturability of the rotor 12 (particularly of the rotor core 16).Yet further, the bridges 122 dampen permeance, resulting in less torqueripple under load. Even further still, provision of the outer bridges122 simplifies formation of the preferred overmolded retention structure22.

With further regard to the retention structure 22, it is noted that thebridges 122 as described above provide structural integrity to the rotorcore 16 in a most preferred embodiment. However, it is permissible forthe retention structure 22 to also facilitate securement of the polesegments 68 relative to one another, particularly in alternativeembodiments in which fewer or no outer bridges are provided.

Interior Bridges

In a preferred embodiment, the rotor 12 also includes a plurality ofinterior bridges 128. Each of the interior bridges 128 preferablyextends between and interconnects a corresponding one of the polesegments 68 to the support structure 102. Similarly to the outer bridges122, the interior bridges 128 thus provide a degree of structuralrigidity to the rotor core 16 as a whole.

Preferably, the interior bridges 128 each comprise a plurality ofaxially spaced apart bridge segments 130. More particularly, as notedpreviously, each of the laminations 70 preferably includes a pluralityof arcuately arranged pole segment portions 72. Furthermore, eachlamination 70 also preferably includes a plurality of the bridgesegments 130, each of which extends from a corresponding one of the polesegment portions 72. Each interior bridge 128 is cooperatively formed bya subset of the laminations 70 and, more particularly, by the bridgesegments 130 of a subset of the laminations 70.

For instance, in the illustrated embodiment, axially alternating ones ofthe rotor laminations 70 form each of the bridge segments 130, withaxially alternating ones of the rotor laminations 70 therebycooperatively forming each interior bridge 128.

Preferably, the laminations 70 are identical (within manufacturingtolerances) or at least substantially identical to one another. However,axially adjacent ones of the laminations 70 are arcuately (i.e.,angularly) offset from one another by a rotation angle S. Moreparticularly, with reference to FIGS. 6a and 7, the rotation angle S ispreferably such that the bridge segments 130 a of a first one of thelaminations 70 a do not overlie the bridge segments 130 b of animmediately adjacent second lamination 70 b. Furthermore, the bridgesegments 130 c of a third lamination 70 c, wherein the second lamination70 b is disposed directly between the first and third laminations 70 aand 70 c, respectively, do align with the bridge segments 130 a of thefirst lamination 70 a but are offset from (i.e., not aligned with) thebridge segments 130 b of the second lamination 70 b). In such a manner,a bridge 128 having axial spaces 132 therein is formed.

Preferably, each of the laminations 70 includes fewer of the bridgesegments 130 than pole segment portions 72. Most preferably, forinstance, each lamination 70 includes half as many bridge segments 130as pole segment portions 72, with the bridge segments 130 being evenlyarcuately distributed. That is, the bridge segments 130 preferablyextend from arcuately alternating ones of the pole segment portions 72,such that the pole segments portions 72 preferably include arcuatelyalternating bridged pole segment portions 72 a and non-bridged polesegment portions 72 b. For instance, as illustrated, it is mostpreferred that each lamination 70 include ten (10) pole segment portions72 and five (5) bridge segments 130, such that five (5) bridged polesegments 72 a are provident in arcuately alternating fashion with five(5) non-bridged pole segments 72 b.

It is also noted that, in alternative embodiments, the laminations mightbe substantially non-identical in such a manner as to achieve similarlyaxially discontinuous bridges. For instance, laminations including onlybridged pole segments might be stacked alternately with laminationsincluding only non-bridged pole segments. However, other deficienciesaside, such an alternative embodiment would fail to achieve the axiallyoffset bridge configuration of the preferred embodiment, whereby, at agiven axial position, bridge segments 130 and spaces 132 alternatearcuately. That is, arcuately adjacent ones of the bridges 128 arepreferably axially offset from one another by the thickness of alamination 70. With reference to FIGS. 6 and 6 a, for instance, bridges128 a include uppermost bridge segments 130, while bridges 128 b,alternating arcuately with bridges 128 a, include uppermost spaces 132.

In a preferred embodiment, each of the pole segments 68 presents agenerally radially extending geometric centerline T. The geometriccenterlines Tare arcuately offset from one another about the axis A by apole segment spacing angle U. Preferably, in keeping with theabove-described preferred interior bridge 128 configuration, therotation angle S and the spacing angle U are at least substantiallyequal.

As noted previously, the rotor core 16 preferably includes ten (10) ofsaid pole segments 68. The pole segments 68 are preferably equallyspaced apart, such that the geometric centerlines T thereof are eachspaced apart by about thirty-six (36) degrees. Thus, in a preferredembodiment of the present invention, the rotation angle S and thespacing angle U are each about thirty-six (36) degrees.

As will be apparent to one of ordinary skill in the art, a differentnumber of pole segments would preferably result in correspondinglydifferent rotation angle due to the change in the spacing angle. Forinstance, an eight-pole rotor would preferably include laminationsrotated about forty-five (45) degrees relative to one another.

It is particularly noted that, although it is preferred that each of thesubsets comprises bridge segments 130 of axially alternating ones of thelaminations 70, alternative spacing is permissible. For instance, eachbridge could instead comprise bridge segments from every thirdlamination; each bridge could comprise sets of multiple axially adjacentbridge segments, each spaced apart by one or more laminations; thebridges could be axially irregular.

Preferably, the bridge segments 130 in a given bridge 128 are at leastsubstantially axially aligned such that, in turn, the bridges 128 in abroad sense are at least substantially straight. However, single- orbi-directional skewing of the bridge segments and the associated bridge(e.g., to form a helical bridge or a zig-zag bridge), as well as of theassociated pole segment portions and pole segment as a whole, ispermissible according to some aspects of the present invention. That is,in some alternative embodiments, the rotation angle might vary from thepole segment spacing angle for one or more of the laminations.

In a preferred embodiment, as noted previously, each pole segment mainbody 82 preferably presents a body face 86, a pair of arcuately spacedsides 90 extending generally radially from the body margins 88, and aninner face 92 extending between and interconnecting the sides 90. Agenerally arcuate minimum pole segment width G, equal to the previouslydescribed inner face length G, is preferably defined at the inner face92. Each of the interior bridges 128 preferably presents a minimumgenerally arcuate interior bridge width V. The bridge width V ispreferably between about twenty five (25) percent and about seventy-five(75) percent of the minimum pole segment width G. Most preferably, thebridge width V is about half of the pole segment width G. Otherproportions fall within the scope of some aspects of the presentinvention, however.

In a preferred embodiment, as illustrated, the bridge width V is abouttwenty-five thousandths (0.025) inches. As noted previously, the innerface length or minimum pole segment width G is preferably about fiftythousandths (0.050) inches.

The above-described axially discontinuous interior bridges 128 provideadvantageous structural rigidity to the rotor 12 while decreasing theflux leakage associated with conventional (i.e., axially continuous,etc.) bridges or with designs in which the rotor core includes a hubinto which pole segments connect directly (e.g., via dovetailconnections, integral formation, etc.). This reduced flux leakageresults in more torque-producing flux across the previously describedgap 60, improving motor performance in a broad sense. Such reducedleakage also preferably enables magnetization of the rotor core 16 afterassembly, leading to increased assembly efficiency and associated costsavings.

Although the above description presents features of preferredembodiments of the present invention, other preferred embodiments mayalso be created in keeping with the principles of the invention.Furthermore, these other preferred embodiments may in some instances berealized through a combination of features compatible for use togetherdespite having been presented independently in the above description.

The preferred forms of the invention described above are to be used asillustration only and should not be utilized in a limiting sense ininterpreting the scope of the present invention. Obvious modificationsto the exemplary embodiments, as hereinabove set forth, could be readilymade by those skilled in the art without departing from the spirit ofthe present invention.

The inventors hereby state their intent to rely on the Doctrine ofEquivalents to determine and assess the reasonably fair scope of thepresent invention as pertains to any apparatus not materially departingfrom but outside the literal scope of the invention set forth in thefollowing claims.

What is claimed is:
 1. A rotor for use in an electric motor androtatable about an axis, said rotor comprising: a plurality of magnetsarranged arcuately about the axis; and a core including a plurality ofarcuately arranged pole segments alternating with the magnets, such thateach of the magnets is at least in part interposed between adjacent polesegments, said pole segments at least in part cooperatively presentingan annular core face, said core face at least in part defining a coreenvelope, said envelope defining a core radius, each of said polesegments including— a main body presenting a body face extendingconcentrically with the axis and disposed along the envelope, said bodyface presenting a pair of arcuately spaced apart body edges, and a pairof ears each extending generally arcuately outwardly from acorresponding one of the body edges, each of said ears presenting asubstantially flat ear face extending directly from the correspondingone of the body edges, each of said ear faces defining a taper anglerelative to a tangent plane defined at the corresponding one of the bodyedges, each of said ear faces being disposed radially inside theenvelope and presenting a radially innermost ear edge disposed radiallyinwardly of said envelope by an ear recess distance, said taper anglebeing between about 4 degrees and about 8 degrees, said ear recessdistance being between about 0.2% and 0.5% of said core radius.
 2. Therotor of claim 1, said taper angle being about 5.25 degrees.
 3. Therotor of claim 2, said ear recess distance being about 0.36% of saidcore radius.
 4. The rotor of claim 1, said body face extending along abody arc angle, each of said ear faces extending along an ear arc angle,said body arc angle being between about equal to and about three timeseach ear arc angle.
 5. The rotor of claim 4, said body arc angle beingabout two times each ear arc angle.
 6. The rotor of claim 5, said bodyarc angle being about 15 degrees, said ear arc angle being about 7.5degrees.
 7. The rotor of claim 6, said core including ten of said polesegments.
 8. The rotor of claim 1, said core further including aplurality of outer bridges extending between and connecting adjacentones of the ears.
 9. The rotor of claim 8, each of said outer bridgespresenting a bridge face, each of said ear faces and an adjacent one ofthe bridge faces defining an ear-bridge angle therebetween, saidear-bridge angle being between about 172 degrees and about 176 degrees.10. The rotor of claim 9, said ear-bridge angle being about 174.5degrees.
 11. The rotor of claim 8, each of said outer bridges presentinga radially outer bridge face, each of said radially outer bridge facesbeing disposed radially inwardly of said envelope by a bridge recessdistance, said bridge recess distance being between about 0.35% and0.65% of said core radius.
 12. The rotor of claim 11, said bridge recessdistance being about 0.5% of said core radius.
 13. The rotor of claim 8,each of said outer bridges having a generally radial thickness, saidbridge thickness being between about 1% and about 2% of said coreradius.
 14. The rotor of claim 13, said bridge thickness being about1.5% of said core radius.
 15. The rotor of claim 1, each of said mainbodies presenting a pair of arcuately spaced apart sides, each of saidears presenting a rear face disposed radially inwardly of thecorresponding ear face and extending directly from a corresponding oneof the sides, said rear face and said corresponding one of the sidesdefining an obtuse rear angle therebetween.
 16. The rotor of claim 15,said rear angle being between about 120 degrees and about 150 degrees.17. The rotor of claim 16, said rear angle being about 135 degrees. 18.The rotor of claim 1, said rotor further including a support structuredisposed radially inwardly of said pole segments, said core furtherincluding a plurality of interior bridges, each of said interior bridgesextending between and interconnecting a corresponding one of said polesegments to said support structure, each of said interior bridgescomprising a plurality of axially spaced apart interior bridge segments.19. The rotor of claim 18, said core comprising a plurality of stackedlaminations, said laminations cooperatively defining the pole segmentsand the interior bridges. said laminations being at least substantiallyidentical to one another. axially adjacent ones of said laminationsbeing arcuately offset from one another about the axis by a rotationangle, said rotation angle being such that axially alternating ones ofsaid laminations cooperatively define each of said interior bridges. 20.The rotor of claim 1, said core envelope being a right circularcylindrical core envelope.